Liner for a protective helmet

ABSTRACT

A helmet includes an outer shell, an energy-absorbing layer disposed inside the outer shell, and a liner disposed inside of the energy-absorbing layer. The liner includes a central portion configured to extend along a longitudinal axis that runs between a front portion of the helmet and a rear portion of the helmet, a first side portion releasably coupled to the central portion, and a second side portion releasably coupled to the central portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 61/008,976, filed Dec. 21, 2007, the entire contents of which areincorporated by reference.

BACKGROUND

The present invention relates to protective helmets, such as motorcyclehelmets. More particularly, the invention relates to a protective helmetwith a customizable fit. Although most protective helmets are currentlyavailable in a range of standardized sizes to roughly match the size ofa wearer's head, the precise fit of a conventional helmet is generallynot adjustable for matching the particular shape of a wearer's head.Furthermore, conventional helmets are not able to be precisely sized forpersons with head sizes in between two standardized sizes.

SUMMARY

In one embodiment, the invention provides a helmet including an outershell, an energy-absorbing layer disposed inside the outer shell, and aliner disposed inside of the energy-absorbing layer. The liner includesa central portion configured to extend along a longitudinal axis thatruns between a front portion of the helmet and a rear portion of thehelmet, a first side portion releasably coupled to the central portion,and a second side portion releasably coupled to the central portion.

In another embodiment, the invention provides a helmet including anouter shell, an energy-absorbing layer disposed inside the outer shell,and a liner disposed inside of the energy-absorbing layer and configuredto contact the head of a wearer when the helmet is worn by the wearer.The liner includes a central portion configured to extend along alongitudinal axis that runs between a front portion of the helmet and arear portion of the helmet, a first side portion coupled to the centralportion and defining a first pocket, a second side portion coupled tothe central portion and defining a second pocket, and a pair of inserts.Each one of the inserts are insertable into one of the first and secondpockets to increase the thickness of the corresponding side portion tocustomize the size of the liner and the fit of the helmet on the head ofthe wearer.

In yet another embodiment, the invention provides a method ofcustomizing the fit of a helmet for a wearer. An outer shell is providedwith an energy-absorbing layer disposed inside the outer shell. A lineris provided releasably coupled to the energy-absorbing layer. The lineris configured to contact the head of the wearer when the helmet is wornby the wearer. The liner includes a central portion configured to extendalong a longitudinal axis that runs between a front portion of thehelmet and a rear portion of the helmet. The liner further includesfirst and second side portions releasably coupled to the centralportion. The thickness of at least a portion of the liner is adjusted toadjust the fit of the helmet for the head of the wearer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom view of a protective helmet having a liner embodyingthe present invention.

FIG. 2 is a bottom view of the protective helmet of FIG. 1 with theliner removed.

FIG. 3 is a bottom view of the liner removed from the protective helmetof FIG. 1, showing two side flaps in a first orientation with respect toa central portion of the liner.

FIG. 4 is a bottom view of the liner of FIG. 3, showing one of the sideflaps rotated to a second orientation with respect to the centralportion of the liner.

FIG. 5 is a top view of the liner of FIG. 3, showing one of the sideflaps detached from the central portion of the liner.

FIG. 6 is a perspective view of the detached side flap of FIG. 5,illustrating a pocket formed therein.

FIG. 7 is a perspective view of a fit-customizing pad insertable intoone of the pockets of the side flaps of the liner.

FIG. 8 is a perspective view illustrating the fit-customizing pad ofFIG. 7 partially inserted into the pocket of a side flap of the liner.

FIG. 9 is a perspective view illustrating the fit-customizing pad ofFIG. 7 fully inserted into the pocket of the side flap of the liner.

FIG. 10 is a bottom view of a liner according to another constructionfor use with the protective helmet of FIG. 1.

FIG. 11 is a top view of the liner of FIG. 7, illustratingfit-customizing pads insertable into side flaps of the liner.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass both direct and indirectmountings, connections, supports, and couplings. Further, “connected”and “coupled” are not restricted to physical or mechanical connectionsor couplings.

DETAILED DESCRIPTION

FIG. 1 illustrates a protective helmet 20. In the illustratedconstruction, the helmet 20 is a motorcycle helmet, particularly ahalf-shell or “beanie” type motorcycle helmet. However, features of thehelmet 20 and portions thereof as described below may be applied tovarious styles of helmets used for various activities. The helmet 20includes an outer shell 24, which is generally a rigid, syntheticmaterial. An energy-absorbing layer 28 (FIG. 2) is positioned inside theouter shell 24. The energy-absorbing layer 28 may be constructed ofpolystyrene foam, for example, and may be partially covered by a skin 30for enhanced appearance and/or comfort. A comfort liner 32 (FIGS. 1 and3-5) is positioned inside the energy-absorbing layer 28. The liner 32 isadjacent a head of a wearer of the helmet 20 and provides comfort andappropriate fit for the wearer. A retention system 36 provides means forsecuring the helmet 20 to the wearer's head. The helmet 20 furtherincludes a visor 38 as shown in FIGS. 1 and 2.

As described in further detail below, the liner 32 is removable,reconfigurable, and exchangeable, providing a custom fit for a varietyof different wearers having different head sizes and/or shapes.Referring to FIG. 3, the liner 32 includes a central portion 40extending along a longitudinal direction of the helmet 20 (from front torear). The central portion 40 generally extends to cover the top of thewearer's head from the forehead to the rear of the skull, but generallydoes not cover the sides of the wearer's head. Rather, a pair of flapsor side portions 44 are coupled to the central portion 40 and positionedto lie against the sides of the wearer's head. The side portions 44 arereleasably coupled to the central portion 40 adjacent a front end 40A ofthe central portion 40, which is also the front end of the liner 32(FIGS. 3-5).

A rear end 40B of the central portion 40, which is also the rear end ofthe liner 32, defines a longitudinal channel 46 for receiving agathering of the wearer's hair in a pony tail, braid, etc. The channel46 is configured to extend along the back of the wearer's neck toreceive the gathering of hair, if present, in order to prevent apressure point or general discomfort to the wearer due to the pinchingof the hair within the helmet 20.

FIG. 3 illustrates both of the side portions 44 in a first orientationwith respect to the central portion 40. In the first orientation, theside portions 44 extend generally along the central portion 40. Itshould be noted that FIG. 3 illustrates the liner 32 in a flattenedstate, and when positioned within the helmet 20, the liner 32 assumes anarched shape such that the side portions 44 complement the sides of thecentral portion 40. As shown in FIGS. 4-6, each of the side portions 44has a curved edge 48 configured to lie adjacent the respective sides ofthe central portion 40 when the liner 32 is positioned within the helmet20.

As shown in FIG. 2, the helmet 20 includes a pair of front fasteners 52,a pair of rear fasteners 54, and a pair of intermediate fasteners 56 forcoupling the liner 32 to the energy-absorbing layer 28 and/or the skin30. With further reference to FIG. 5, the liner 32 includes front, rear,and intermediate fasteners 62, 64, 66 corresponding to the respectivefront, rear, and intermediate fasteners 52, 54, 56 on theenergy-absorbing layer 28. The intermediate fasteners 66 of the liner 32are formed on the side portions 44, while the front and rear fasteners62, 64 of the liner 32 are formed on the central portion 40. Asillustrated, the rear fasteners 64 of the liner 32 are formed adjacentthe rear end 40B of the central portion 40.

The front fasteners 62 on the liner 32 are configured to releasablyattach the side portions 44 to the central portion 40 in addition toreleasably attaching the front portion of the liner 32 to theenergy-absorbing layer 28. As shown in FIGS. 5 and 8, each side portion44 includes a flange 70 including an aperture 72. The apertures 72receive the front fasteners 62 on the central portion 40 of the liner 32(e.g., by a press fit, snap fit, etc.) such that the side portions 44are releasably coupled to the central portion 40. The flanges 70 of theside portions 44 allow the side portions 44 to rotate relative to thecentral portion 40 when the liner 32 is removed from the helmet 20(FIGS. 4 and 5 illustrate one of the side portions 44 rotated to asecond orientation relative to the central portion 40). When attached tothe central portion 40, the flanges 70 do not interfere with thecoupling of the front fasteners 62 of the liner 32 to the frontfasteners 52 of the energy-absorbing layer 28. In alternateconstructions, the side portions 44 are coupled to the central portion40 at a separate location on the liner 32 from the front fasteners 62,which releasably couple the front portion of the liner 32 to theenergy-absorbing layer 28.

In the illustrated construction, the front, rear, and intermediatefasteners 62, 64, 66 of the liner 32 are snaps. The front, rear, andintermediate fasteners 52, 54, 56 on the energy-absorbing layer 28 arealso snaps in the illustrated construction such that the liner 32 isreleasably attachable to the energy-absorbing layer 28 by snapping. Inlieu of snaps, alternate means (e.g., screws, buttons, detentarrangements, adhesive strips, hook-and-loop strips, etc.) forreleasably mounting the liner 32 in the helmet 20 may be provided.

FIGS. 5, 6, 8, and 9 illustrate pockets 76, which are formed in the sideportions 44. The pockets 76 receive one or more fit-customizing insertsor pads 80 (FIGS. 7-9). Each pad 80 has a given thickness, but alternatepads may be provided with different thicknesses or additional pads 80may be provided in various quantities in order to change the effectiveinterior size and/or shape of the helmet 20 by altering the thickness ofthe liner 32 in the area of the side portions 44. The pockets 76 make itquickly and easily possible to modify the helmet 20 to provide acustomized fit.

Furthermore, the fit of the helmet 20 may be customized for a particularindividual by replacing the liner 32 or portions thereof with a similaralternative that has an alternate size, shape, and/or thickness. Forexample, the side portions 44 can be replaced by thicker or thinner sideportions (not shown) that attach to the central portion 40 at the frontfasteners 62 of the central portion 40. An alternate central portion(not shown) having a thickness different from the original centralportion 40 may also be provided to replace the original central portion40, providing the helmet 20 with an alternate fit.

FIGS. 10 and 11 illustrate another liner 132 configured for use as partof the helmet 20 of FIGS. 1 and 2. The liner 132 of FIGS. 10 and 11 issimilar in most respects to the liner 32 described above.

The liner 132 includes a central portion 140 and a pair of side portions144 that are releasably coupled to the central portion 140 adjacent afront end 140A thereof. Each side portion 144 includes a flange 170having an aperture 172 therein for attaching to the front fasteners 162of the liner 132. The front fasteners 162 are additionally releasablycoupled to the front fasteners 52 on the energy-absorbing layer 28. Theside portions 144 are provided with intermediate fasteners 166 that arereleasably coupled to the intermediate fasteners 56 on theenergy-absorbing layer 28. Rear fasteners 164, provided adjacent a rearend 140B of the central portion 140, are releasably coupled to the rearfasteners 54 on the energy-absorbing layer 28.

In the illustrated construction, and similar to the liner 32 of FIGS.3-9, the side portions 144 of the liner 132 may be releasably attachedto the front fasteners 162 (or another location) on the central portion140 adjacent the front end 140A. The flanges 170 of the side portions144 do not interfere with the releasable coupling of the liner 132 tothe energy-absorbing layer 28 and furthermore, allow the side portions144 to rotate relative to the central portion 140 about the frontfastener 162 (as shown by the double-arrows 182 in FIG. 11) when theliner 132 is removed from the helmet 20.

As shown in FIGS. 10 and 11, the side portions 144 are generallyrectangular or trapezoidal in shape and do not include arched side edgesconfigured to complement the sides of the central portion 140. The sizeand/or shape of the side portions 144 may provide the helmet 20 with analternate fit, as compared to the side portions 44 shown in FIGS. 3-6and 8-9. Thus, the side portions 44, 144 may be interchanged with eachother on a single liner central portion 40, 140 to reconfigure the liner32, 132 and customize the fit for different wearers having differenthead sizes and/or shapes.

The side portions 144 are provided with respective pockets 176, whichallow the helmet 20 having the liner 132 to be further customized forfit. Each pocket 176 is configured to receive one or morefit-customizing inserts or pads 180 of different thicknesses or providedin different quantities in order to change the effective interior sizeand/or shape of the helmet 20 by altering the thickness of the liner 132in the area of the side portions 144. The pockets 176 andinterchangeable pads 180 make it quickly and easily possible to modifythe helmet 20 to provide a customized fit.

The liners 32, 132 described above enable one or more methods ofcustomizing the helmet 20 for fitting the heads of one or more wearers.For example, the liner 32, 132 may be removed from the helmet 20 andcustomized by detaching the side portions 44, 144 from the centralportion 40, 140 and releasably attaching side portions 44, 144 having analternate size and/or shape. For example, there may be provided “small”,“medium”, and “large” side portions 44, 144, which can be exchanged tore-configure the liner 32, 132 and adjust the size of the helmet 20.Additionally, a given liner 32, 132 may be interchangeable betweenhelmets 20 having various sized outer shells 24 and energy-absorbinglayers 28.

Furthermore, the liner 32, 132 (provided with side portions 44, 144 andno pads 80, 180) may be detached from the energy-absorbing layer 28 sothat the side portions 44, 144 may be altered by inserting one or moreof the pads 80, 180 into the pockets 76, 176 therein to customize thesize of the liner 32, 132 and the fit of the helmet 20 on the head of awearer. For a given wearer, additional pads 80, 180 may be added (orpads of increasing thickness may be exchanged) until the liner 32, 132is of an appropriate size so that the helmet 20 is customized to fit thehead of the wearer (i.e., providing a snug fit without pressure points).

Thus, the invention provides, among other things, a customizable helmethaving a removable, reconfigurable, and exchangeable liner andremovable/interchangeable components thereof.

1. A helmet comprising: an outer shell; an energy-absorbing layerdisposed inside the outer shell; and a liner disposed inside of theenergy-absorbing layer, the liner including a central portion configuredto extend along a longitudinal axis that runs between a front portion ofthe helmet and a rear portion of the helmet, a first side portionreleasably coupled to the central portion, and a second side portionreleasably coupled to the central portion.
 2. The helmet of claim 1,further comprising a plurality of fasteners on the energy-absorbinglayer, the liner having a plurality of fasteners corresponding to theplurality of fasteners on the energy-absorbing layer for releasablyattaching the liner to the energy-absorbing layer.
 3. The helmet ofclaim 2, wherein the plurality of fasteners of the liner includes a pairof front fasteners adjacent a front end of the central portion of theliner, the pair of front fasteners configured to attach to a pair ofcomplementary fasteners on the energy-absorbing layer, wherein the firstand second side portions are releasably coupled to the central portionat the pair of front fasteners.
 4. The helmet of claim 2, wherein theliner includes an alternate central portion having a plurality offasteners corresponding to the plurality of fasteners on theenergy-absorbing layer for releasably attaching the alternate centralportion to the energy-absorbing layer in place of the original centralportion, the alternate central portion having at least one of adifferent size and a different shape compared to the original centralportion to customize the liner and the fit of the helmet on the head ofa wearer, the first and second side portions being configured toreleasably attach to the alternate central portion.
 5. The helmet ofclaim 1, wherein the first side portion and the second side portion arepivotally coupled to the central portion.
 6. The helmet of claim 1,wherein each of the first side portion and the second side portionincludes a pocket, the helmet further comprising a pair of inserts, eachinsert of the pair of inserts insertable into a respective pocket of thefirst and second side portions to increase the thickness of the sideportions to customize the size of the liner and the fit of the helmet onthe head of a wearer.
 7. The helmet of claim 1, further comprising athird side portion and a fourth side portion, the third and fourth sideportions being interchangeable with the first and second side portionsand having at least one of a different size and shape to customize theliner and the fit of the helmet on the head of a wearer.
 8. A helmetcomprising: an outer shell; an energy-absorbing layer disposed insidethe outer shell; and a liner disposed inside of the energy-absorbinglayer, the liner configured to contact the head of a wearer when thehelmet is worn by the wearer, the liner including a central portionconfigured to extend along a longitudinal axis that runs between a frontportion of the helmet and a rear portion of the helmet, a first sideportion coupled to the central portion and defining a first pocket, asecond side portion coupled to the central portion and defining a secondpocket, and a pair of inserts, each one of the pair of inserts beinginsertable into one of the first and second pockets to increase thethickness of the corresponding side portion to customize the size of theliner and the fit of the helmet on the head of the wearer.
 9. The helmetof claim 8, further comprising a plurality of fasteners on theenergy-absorbing layer, the liner having a plurality of fastenerscorresponding to the plurality of fasteners on the energy-absorbinglayer for releasably attaching the liner to the energy-absorbing layer.10. The helmet of claim 9, wherein the plurality of fasteners of theliner includes a pair of front fasteners adjacent a front end of thecentral portion of the liner, the pair of front fasteners configured toattach to a pair of complementary fasteners on the energy-absorbinglayer, wherein the first and second side portions are releasably coupledto the central portion at the pair of front fasteners.
 11. The helmet ofclaim 9, wherein the liner includes an alternate central portion havinga plurality of fasteners corresponding to the plurality of fasteners onthe energy-absorbing layer for releasably attaching the alternatecentral portion to the energy-absorbing layer in place of the originalcentral portion, the alternate central portion having at least one of adifferent size and a different shape compared to the original centralportion to customize the liner and the fit of the helmet on the head ofa wearer, the first and second side portions being configured toreleasably attach to the alternate central portion.
 12. The helmet ofclaim 1, wherein the first side portion and the second side portion arepivotally coupled to the central portion.
 13. The helmet of claim 8,further comprising a second pair of inserts, wherein each insert of thesecond pair of inserts has a thickness greater than each insert of thefirst pair of inserts, the second pair of inserts being insertable intothe first and second pockets to replace the first inserts and providethe corresponding side portions with a thicknesses greater than thatprovided by the first pair of inserts.
 14. The helmet of claim 8,further comprising a third side portion and a fourth side portion, thethird and fourth side portions being interchangeable with the first andsecond side portions and having at least one of a different size andshape to customize the liner and the fit of the helmet on the head ofthe wearer, each one of the pair of inserts further being insertableinto respective pockets of the third and fourth side portions toincrease the thickness of the third and fourth side portions to furthercustomize the size of the liner and the fit of the helmet on the head ofthe wearer.
 15. A method of customizing the fit of a helmet for aparticular wearer comprising: providing an outer shell; providing anenergy-absorbing layer disposed inside the outer shell; providing aliner releasably coupled to the energy-absorbing layer, the linerconfigured to contact the head of a wearer when the helmet is worn bythe wearer, the liner including a central portion configured to extendalong a longitudinal axis that runs between a front portion of thehelmet and a rear portion of the helmet, the liner further includingfirst and second side portions releasably coupled to the centralportion; and adjusting the thickness of at least a portion of the linerto adjust the fit of the helmet for the head of the wearer.
 16. Themethod of claim 15, wherein adjusting the thickness of at least aportion of the liner includes detaching the first and second sideportions from the central portion, and releasably coupling a third sideportion and a fourth side portion to the central portion, the third andfourth side portions having thicknesses different from the first andsecond side portions.
 17. The method of claim 15, wherein adjusting thethickness of at least a portion of the liner includes placing insertsinto respective pockets of each of the first and second side portions toincrease the thicknesses of the first and second side portions.
 18. Themethod of claim 15, wherein the helmet is provided with removableinserts in pockets of the first and second side portions, the step ofadjusting the thickness of at least a portion of the liner includingremoving the inserts from the pockets to reduce the thickness of thefirst and second side portions.
 19. The method of claim 15, whereinadjusting the thickness of at least a portion of the liner includesdetaching the central portion from the energy-absorbing layer, andreleasably coupling an alternate central portion to the energy-absorbinglayer, the alternate central portion having a thicknesses different fromthe original central portion.
 20. The method of claim 19, whereinadjusting the thickness of at least a portion of the liner furtherincludes adjusting the thickness of the first and second side portions.